System and approach for water heater comfort and efficiency improvement

ABSTRACT

A system for heating water to improve safety and efficiency. The system may have normal operation measured in time. After a time of normal operation, a water temperature setpoint may be checked. If the setpoint is not at a certain level, normal operation may continue. If the setpoint is within the certain level, water temperature may be measured. If the water temperature is less than a desired level, one or more draws of water may be measured for a preset temperature drop. If the draws do not meet the temperature drop, a return to check the setpoint may be made. If the draws meet the temperature drop, the setpoint may be reduced and a time of normal operation may be measured to determine whether a burn cycle occurs within the time. If not, normal operation may continue; but if so, a return to check the setpoint may be made.

BACKGROUND

The present disclosure pertains to systems designed to heat fluids and particularly to devices that pertain to the efficiency and safety of heating fluids.

SUMMARY

The disclosure reveals a system for heating water in a controlled manner to improve safety and efficiency. The system may have a mode of normal operation measured in terms of time. After a certain amount of time of normal operation, a temperature setpoint of the system may be checked. If the setpoint is not at a certain level, then normal operation may continue. If the setpoint is at the certain level, then water temperature of the system may be measured. If the water temperature is less than a desired level, then one or more draws of water may be checked for a preset temperature drop. If the draws do not meet the temperature drop, then a return to the setpoint may be made with subsequent actions as described herein. If the draws meet the temperature drop, then the setpoint may be reduced and normal operation may be measured in terms of time to determine if a burn cycle occurs within a preset amount of time. If not, then normal operation may continue; but if so, a return to a setpoint check may be made along with the subsequent actions as noted.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a diagram of a water heater that incorporates the present system and approach for heating water;

FIG. 2 is a diagram of an illustrative example of a controller for a water heater;

FIG. 3 is a diagram of a general water heater flow chart; and

FIG. 4 is a diagram of water temperature control of a water heater system to prevent generating temperatures of water beyond a certain temperature to improve safety and energy savings.

DESCRIPTION

The present system and approach may incorporate one or more processors, computers, controllers, user interfaces, wireless and/or wire connections, and/or the like, in an implementation described and/or shown herein.

This description may provide one or more illustrative and specific examples or ways of implementing the present system and approach. There may be numerous other examples or ways of implementing the system and approach.

Residential and commercial water heaters may use a ten to fifteen degree differential to maintain tank temperature. The temperature control may work sufficiently to deliver hot water; however, after multiple draws, the water tank can begin to stratify, leading to a set point at 135 degrees Fahrenheit (F) producing a temperature near 150 degrees F. at the top of the tank for supply. The hot water is not necessarily safe or comfortable for the user and also may waste more energy by increasing the top of the tank's ambient differential. The present algorithm may limit the return to a setpoint only during excess demand cycles. The reduction in return to setpoint may still maintain sufficient hot water; however, the burner advance turnoff could protect the user from scalding and excess energy consumption.

The burning algorithm may track the gas valve history for the prior four hours of operation. A counter may track the number of burner on and off and total burner on time of each recovery. In the condition of 2 or more burn cycles in one hour, the algorithm may go live and on the third reheat cycle, the return to setpoint may be limited from zero to ten degrees F., depending on a total prior draw load and total burn time tracked leading up to the 3rd draw with in that hour. The reduction in setpoint may allow the regeneration of heat without the overshoot of tank temperature at the top of the tank. The hot water tank algorithm's reduction in set point may stay live for up to four hours to allow the tank to equalize tank temp. At that point, the return to set point may occur and water temp may rise to the desired tank temp within two to three degrees F.

FIG. 1 is a diagram of a water heater 30 that may incorporate the present system and approach for heating water. A water tank 32 may have an input supply pipe or drip tube 44 for receiving fresh water and an output pipe or tube 46 for drawing water, particularly heated water as needed. Tank 32 may have an inner surface 42 and an outer surface 52. Around tank 32 may be an insulating layer 34 and an external shell 36. In tank 32 may be a rust inhibiting layer 50. Toward a bottom of tank 32 may be a drainage valve 48. Water heater 30 and tank 32 may have a top surface 54. At a bottom of heater 30 and tank 32 at a bottom surface 56 may be a heater 38 which can use electricity, gas or a combination to create heat for increasing a temperature of water in tank 32. In the diagram of FIG. 1, a gas burner 58 may be used as an illustrative example of heater 38. There may be a combustion chamber 63 that is supplied with a fuel such as gas in a tube 66. Combustion chamber 63 may have an enclosure 59 and or exhaust pipe flue 66 that runs from chamber 63 through tank 32 and top surface 54 to an outside exhaust vent.

An ignition source 40 such as a pilot light may be fed fuel from tube 66. A valve 67 may be electrically opened and closed. Valve 67 may close if not kept warm by pilot 60, particular in the event that the pilot 60 is extinguished and cannot light the burner in an event that an electric signal from a controller 40 is a command to open valve 67. Also, if pilot 60 goes out, then a thermal valve (a component of valve 67) connected to pilot 60 closes if not kept warm by pilot 60. The precautionary measures are for preventing a release of gas from a non-functioning burner 38 and pilot 60.

A sensor 64 may be connected to controller 40 to provide a temperature of water in tank 32 to controller 40. Input signals 70, sensor signals 84 and settings 86 may go to controller 40. Control signals 82 may be provided by controller 40. Controller 40 may also have controls and indicators for a user. Examples may be gauges, lights, setting selectors, and the like. A controller 40 may be of various versions of models that vary from simple to complex arrangements. Controller 40 may operate relative to a program or algorithm as indicated herein.

A diagram in FIG. 2 shows an illustrative example of controller 40. Input signals 70 may go to a processing block 72 which may incorporate a processor 71 and memory 78 that are connected to each other. A connection line 84 may connect one or more sensors 64 to a sensor input buffer circuit 74. Sensor signals may be provided by sensor input buffer circuit 74 to processor 71. Settings 86, such as those of temperature and time, and the like, may go to settings buffer circuit 80 and then on to processor 71. Output control signals may proceed from processor 71 to along connection line 82 to one or more valve actuators, and other actuators or components, and the like. Indicator signals may proceed from processor 71 along a connection line 83 to various instruments such as displays, gauges, indicator lights, sound emanating devices, and the like. Temperature and other setpoints may be entered along connection line 86 to a settings buffer circuit 80. From circuit 80, setting signals may go to processor 71. Entries from inputs may be from thermostats, keyboards, tunable knobs, switches, and so forth.

FIG. 3 is a diagram of a general water heater flow chart. Symbols may represent blocks, steps, statuses, activity or other items, even though they might be referred to as “symbols” for purposes of the diagram. Symbol 91 may indicate that a water temperature control system is in standby. A question of whether water temperature is less that a setpoint minus tolerance may be asked at symbol 92. If an answer is no, then there may be a return to standby. If the answer is yes, then a heating cycle (burn cycle) may occur at symbol 93. At symbol 94, a question of whether the water temperature is greater than the setpoint plus tolerance may be asked. If an answer is no, then the heating cycle may occur. If the answer is yes, then a return to standby may be made.

FIG. 4 is a diagram of water temperature control that may prevent a water heater system from generating temperatures of water beyond a certain temperature to improve safety and energy savings. Symbol 11 may represent normal operation of a water heater. A timer may be started at symbol 12. A question at symbol 13 may ask whether the timer has run for more than one hour. If an answer is no, then a return may be made to symbol 11 and symbol 12. The question at symbol 13 may be asked again. If the answer is yes, then a question at symbol 14 may be asked as to whether a set point of the water heater is greater than 125 degrees Fahrenheit (F) or less than 150 degrees F. If an answer is no, then a return may be made to symbol 11 of normal operation. If the answer is yes, then a question at symbol 15 may be asked as to whether a water temperature in the water heater is less than C*(88 degrees F.). If the answer is yes, then a return to normal operation at symbol 11 may occur. If the answer is no, then at symbol 16 a question asked may be whether two draws within X minutes (60<X<75) with a temperature drop greater than D*(˜25 degrees F.) in M (˜10) minutes on each draw. If an answer is no, then a return to symbol 14 may be made with sequences to follow symbol 14 as indicated herein. If the answer is yes, then the set point may be reduced by Y*(˜5 to 10 degrees F.) at symbol 17. Subsequently, a timer may be started and normal operation can occur at symbol 18. A question may then be asked at symbol 19 as to whether a burn cycle is within four hours. If an answer is no, then a return to normal operation at symbol 11 may occur. If the answer is yes, then a return may be made to symbol 14 with sequences of operation to follow as indicated herein.

To recap, a water heater control mechanism may incorporate a processor having a memory, a temperature sensor situated in a tank of a water heater and connected to the processor, a heater connected to a valve or switch, a setpoint device connected to the processor, an actuator attached to the valve and connected to the processor, and a program situated in the memory. The processor may have a normal operation for controlling temperature of water in the tank relative to a setpoint for temperature of the water. The program may provide steps that incorporate timing a length of normal operation, reading the setpoint device if the timing of a length of the normal operation exceeds a pre-determined time, reading the temperature sensor if a reading of the setpoint device is between two pre-determined temperatures, measuring one or more draws in terms of time and temperature if the reading of the temperature sensor is equal to or greater than a pre-determined temperature, reducing a setting of the setpoint device if the terms of time and temperature are within pre-defined terms of time and temperature for a draw, timing to when a burn cycle occurs, and reading the setpoint device if a time until a burn cycle occurs is greater than a pre-determined time.

If the reading of the setpoint device is not between the two pre-determined temperatures, then the processor may return to normal operation.

A return to reading the setpoint device may occur if the terms of time temperature for a draw are not within the pre-defined terms of time and temperature for a draw.

If the timing of the length of the normal operation does not exceed the pre-determined time, then the processor may continue in normal operation.

The two pre-determined temperatures for the setpoint device may be between A degrees Fahrenheit and B degrees Fahrenheit.

If the reading of the temperature sensor is equal to or less than the pre-determined temperature, then the processor may return to normal operation.

The pre-determined temperature for the temperature sensor may be C degrees Fahrenheit.

The pre-defined terms of time and temperature may incorporate J draws or K pair or pairs of draws with a period between D minutes and E minutes with a temperature drop of F degrees Fahrenheit in G minutes on each draw.

A return of the processor to normal operation may occur if the time until the burn cycle occurs is equal to or less than the pre-determined time.

The pre-determined time for when the burn cycle occurs may be H hours.

Illustrative example numbers for the variables may be A˜125, B˜150, C˜80, D˜60, E˜75, F˜25, G˜10, H˜4, J˜2 and K˜1.

A fluid heater system may incorporate a tank, a heater at the tank, a fluid input on the tank, a fluid output on the tank, a heater control device connected to the heater, a temperature sensor situated in the tank, a temperature setpoint mechanism, a timer, and a processor connected to the heater control device, the temperature sensor, the temperature setpoint mechanism and the timer. The processor may control the heater control device, adjust the temperature setpoint mechanism and operate a timer in response to the temperature sensor, according to a program.

A maximum temperature of a fluid in the tank may be controlled by the processor and heater control device according to the program.

A setpoint on temperature setpoint mechanism may result in a temperature of a fluid in the tank greater than a temperature indicated by the setpoint due to temperature stratification of the fluid in the tank. The program may limit a return to a setpoint just during excess demand cycles, to reduce the temperature of the fluid in the tank increased by temperature stratification.

The heater may be a gas burner. The heater control device may incorporate a valve connected to the gas burner, and an actuator that controls the valve and is connected to the processor. The program may track a history of the valve that reveals a number of times that a burner turns on and off and the total on-time of the burner. After a sequence of a pre-determined number of times that the burner turns on and off, the program may limit a return to the setpoint by a certain number of degrees less than the setpoint of the temperature setpoint mechanism according to the total on-time of the burner and amount of fluid draw from the tank within a given period of time.

The heater may be electric.

Steps of the program may incorporate 1) measuring a time of a normal operation of the processor, 2) checking a setpoint of the temperature setpoint mechanism if a time of the normal operation exceeds an A hour duration, 3) detecting a temperature less than B degrees Fahrenheit of the fluid if the setpoint of the temperature setpoint mechanism is between C degrees and D degrees Fahrenheit to take the processor out of normal operation, 4) making E draws of fluid from the tank within an F minute duration between a G minute duration and an H minute duration with a temperature drop detected by the temperature sensor greater than I degrees Fahrenheit of a J minute duration on each draw occurring that results in reducing the setpoint by K degrees between L degrees and M degrees, or in absence of each draw occurring as such results in going to step 3), 5) measuring a time of another normal operation of the processor, and 6) determining that an electric heat cycle has occurred within an N hour duration and thus resulting in returning to step iii), or determining that an electric heat cycle has not occurred thus resulting in the processor remaining in normal operation.

A, B, C, D, E, F, G, H, I, J, K, L, M, and N may be numbers associated with units as fitting in their context.

One or more items may be selected from a group incorporating A being about 1, B being about 80, C being about 125, D being about 150, E being about 2, F being between G and H, G being about 60, H being about 75, I being about 25, J being about 10, K being between L and M, L being about 5, M being about 10, and N being about 4.

One or more items may be selected from a group comprising A is between 0.05 and 5, B is between 40 and 120, C is 80, D is 200, E is between 1 and 10, F is between G and H, G is 5, H is 250, I is between 5 and 125, J is between 1 and 60, K is between L and M, L is 0, M is 50, and N is between 0.1 and 10.

A water heater may incorporate a tank, a water heater attached to the tank, a control device connected to the water heater, a temperature sensor in the tank, a temperature setpoint mechanism, and a controller connected to the control device, temperature sensor and a temperature setpoint mechanism. The processor may operate according to a program that causes normal operation of the heater to be overridden by an occasional setpoint adjustment to ensure efficiency and a supply safe hot water temperature.

The program may incorporate occasionally checking the setpoint of the temperature setpoint mechanism, continuing normal operation if the setpoint is at an acceptable setting, obtaining a temperature of water in the tank from the temperature sensor if the setpoint is absent from a predetermined setting, returning to normal operation if the temperature of the water is at predetermined magnitude, obtaining a temperature drop evaluation of one or more draws of water if the temperature of the water is absent from a predetermined magnitude, rechecking the setpoint if the temperature drop evaluation is high, reducing the setpoint if the temperature drop evaluation is low, starting timing normal operation of the heater to detect whether a burn cycle occurs within a predetermined period of time, rechecking the setpoint if the burn cycle occurs, and continuing normal operation if a burn cycle does not occur.

U.S. patent application Ser. No. 14/225,308, filed on Mar. 25, 2014, is hereby incorporated by reference.

Any publication or patent document noted herein is hereby incorporated by reference to the same extent as if each individual publication or patent document was specifically and individually indicated to be incorporated by reference.

In the present specification, some of the matter may be of a hypothetical or prophetic nature although stated in another manner or tense.

Although the present system and/or approach has been described with respect to at least one illustrative example, many variations and modifications will become apparent to those skilled in the art upon reading the specification. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the related art to include all such variations and modifications. 

What is claimed is:
 1. A water heater control mechanism comprising: a processor having a memory; a temperature sensor situated in a tank of a water heater, and connected to the processor; a heater connected to a valve or switch; a controller connected to the processor, the controller configured to receive at least a temperature setpoint and communicate the controller setpoint to the processor; an actuator attached to the valve and connected to the processor; and a program situated in the memory; and wherein: the processor has a normal operation for controlling temperature of water in the tank relative to a setpoint for temperature of the water; the program provides steps that comprise: timing a length of normal operation; reading the temperature setpoint if the timing of a length of the normal operation exceeds a first pre-determined time; reading the temperature sensor if a reading of the temperature setpoint is between an upper pre-determined temperature and a lower pre-determined temperature; measuring one or more draws in terms of time and temperature if the reading of the temperature sensor is equal to or greater than said upper pre-determined temperature; reducing a setting of the temperature setpoint if the terms of time and temperature are within pre-defined terms of time and temperature for one of the one or more draws; timing to when a burn cycle occurs from the step of reducing a setting of the temperature setpoint; and reading the temperature setpoint if a time until said burn cycle occurs is greater than a second pre-determined time.
 2. The mechanism of claim 1, wherein if the reading of the temperature setpoint is not between the two pre-determined temperatures, then the processor returns to normal operation.
 3. The mechanism of claim 2, wherein the two pre-determined temperatures for the temperature setpoint are between A degrees Fahrenheit and B degrees Fahrenheit.
 4. The mechanism of claim 2, wherein the pre-determined temperature for the temperature sensor is C degrees Fahrenheit.
 5. The mechanism of claim 1, wherein a return to reading the temperature setpoint occurs if the terms of time temperature for a draw are not within the pre-defined terms of time and temperature for a draw.
 6. The mechanism of claim 5, wherein the pre-defined terms of time and temperature comprise J draws with a period between D minutes and E minutes between the draws with a temperature drop of F degrees Fahrenheit in G minutes on each draw.
 7. The mechanism of claim 1, wherein if the timing of the length of the normal operation does not exceed the pre-determined time, then the processor continues in normal operation.
 8. The mechanism of claim 1, wherein if the reading of the temperature sensor is less than said upper pre-determined temperature, then the processor returns to normal operation.
 9. The mechanism of claim 1, wherein a return of the processor to normal operation if the time until the burn cycle occurs is equal to or less than the pre-determined time.
 10. The mechanism of claim 9, wherein the pre-determined time for when the burn cycle occurs is H hours.
 11. A fluid heater system comprising: a tank; a heater at the tank; a fluid input on the tank; a fluid output on the tank; a heater control device connected to the heater, the heater control device including at least a valve connected to the gas burner and an actuator that controls the valve; a controller configured to receive input signals and control parameters including at least a temperature setpoint and output control signals; a temperature sensor situated in the tank; a timer; and a processor connected to the controller, heater control device, the temperature sensor, and the timer; and wherein: the processor controls the heater control device, adjusts the temperature setpoint and operates a timer in response to the temperature sensor, according to a program; a setpoint above a predetermined threshold of the temperature setpoint can result in a temperature of a fluid in the tank greater than a temperature indicated by the temperature setpoint due to temperature stratification of the fluid in the tank; and the program limits a return to a setpoint just during excess demand cycles, to reduce the temperature of the fluid in the tank increased by temperature stratification.
 12. The system of claim 11, wherein a maximum temperature of a fluid in the tank is controlled by the processor and heater control device according to the program.
 13. The system of claim 11, wherein: the heater is a gas burner; the heater control device is connected to the processor; the program tracks a history of the valve that reveals a number of times that a burner turns on and off and the total on-time of the burner; and after a sequence of a pre-determined number of times that the burner turns on and off, the program limits a return to the temperature setpoint by a certain number of degrees less than the setpoint of the temperature setpoint according to the total on-time of the burner and amount of fluid draw from the tank within a given period of time.
 14. The system of claim 11, wherein the heater is electric.
 15. The system of claim 11, wherein steps of the program comprise: i) measuring a time of a normal operation of the processor; ii) checking a setpoint of the temperature setpoint if a time of the normal operation exceeds an A minute duration; iii) detecting a temperature less than B degrees Fahrenheit of the fluid if the setpoint of the temperature setpoint is between C degrees Fahrenheit and D degrees Fahrenheit to take the processor out of normal operation; iv) making E draws of fluid from the tank within an F minute duration between a G minute duration and an H minute duration with a temperature drop detected by the temperature sensor greater than I degrees Fahrenheit of a J minute duration on each draw occurring then results in reducing the setpoint by K degrees Fahrenheit between L degrees Fahrenheit and M degrees Fahrenheit, or in absence of each draw occurring as such results in going to step iii); v) measuring a time of another normal operation of the processor; and vi) determining that an electric heat cycle has occurred within an N minute duration and thus resulting in returning to step iii), or determining that an electric heat cycle has not occurred thus resulting in the processor remaining in normal operation.
 16. The system of claim 15, wherein A, B, C, D, E, F, G, H, I, J, K, L, M and N are numbers having units as fitting in their respective contexts.
 17. The system of claim 16, wherein one or more items can be selected from a group comprising A is between 5 and 300, B is between 40 and 120, C is 80, D is 200, E is between 1 and 10, F is between G and H, G is 5, H is 250, I is between 5 and 125, J is between 1 and 60, K is between L and M, L is 0, M is 50, and N is between 10 and
 600. 18. A water heater comprising: a tank; a water heater attached to the tank; a control device connected to the water heater, the heater control device including at least a valve connected to the gas burner and an actuator that controls the valve; a temperature sensor in the tank; a temperature setpoint mechanism; and a controller connected to the control device and temperature sensor, the controller configured to receive input signals and control parameters including at least a temperature setpoint and output control signals; and wherein the processor operates according to a program that causes normal operation of the heater to be overridden by an occasional setpoint adjustment to ensure efficiency and a supply safe hot water temperature; and wherein the program comprises: checking the setpoint of the temperature setpoint; continuing normal operation if the setpoint is at an acceptable setting; obtaining a temperature of water in the tank from the temperature sensor if the setpoint is not at a predetermined setting; returning to normal operation if the temperature of the water is at predetermined magnitude; obtaining a temperature drop evaluation of one or more draws of water if the temperature of the water is not at a predetermined magnitude; rechecking to the setpoint if the temperature drop evaluation is high; reducing the setpoint if the temperature drop evaluation is low; starting timing normal operation of the heater to detect whether a burn cycle occurs within a predetermined period of time; rechecking the setpoint if the burn cycle occurs; and continuing normal operation if a burn cycle does not occur. 